Original page (page 2 of 4)

Note: Master cylinder pushrod – to – piston clearance must be checked and adjustments made, if necessary, before installing master cylinder.

1. Master cylinder
2. Pushrod adjustment gauge
3. Locknut
4. Centre shaft
5. Vacuum gauge
6. Tube joint adaptor
7. Vacuum joint tube A
8. Feeler gauge

1. Set the special tool on the master cylinder body; push in the centre shaft until the top of it contacts with the end of the secondary piston and lock it with locknut.
2. Install the special tool upside down on the booster without disturbing the position of the adjusting bolt.
3. Install the master cylinder nuts and tighten to the specified torque.
4. Fit the special tools as shown and connect to engine vacuum. Maintain an engine speed that will deliver 500mm Hg (20 in Hg) vacuum.
5. With a feeler gauge, measure the clearance between the gauge body and the adjusting nut as shown.

Clearance: 0 – 0.4mm (0 – 0.016 in)

Note: If the clearance between the gauge body and the adjusting nut is 0.4mm (0.02 in), the pushrod – to – piston clearance is 0mm. However, if the clearance between the gauge body and adjusting nut is 0mm, the pushrod – to – piston clearance is 0.4mm (0.02 in) or more. Therefore it must be adjusted and rechecked.